Textured laminate flooring

ABSTRACT

A decorated floor panel having a core with a top surface and an opposite bottom surface; a decorative layer coupled to the top surface of the core, the decorative layer having a desired aesthetic appearance; and a wear layer coupled to and substantially covering the decorative layer for protecting the decorative layer. The wear layer has an exposed wear surface with depressions therein of a variable depth below the wear surface, the depressions being arranged to display a desired texture pattern. It is noted that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to ascertain quickly the subject matter of the technical disclosure. The abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims pursuant to 37 C.F.R. § 1.72(b).

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates generally to flooring panels foruse in commercial, industrial or residential environments. Moreparticularly, this invention relates to flooring panels having anaesthetically pleasing appearance provided by texturing imparted to thesurface of the panels. In certain embodiments, the texture is aligned inregistration with a visible graphic design displayed by the panel tofurther enhance the aesthetic appearance of the flooring panel.

[0003] 2. Background Art

[0004] Various laminates, including high pressure laminates andfiberboard core laminates, are commonly used in flooring applications.Fiberboard core laminates used to manufacture flooring products includea plurality of layers, including a fiberboard or organic composite coresection, a decorative layer, and a hard and flat protective wear layerof resin-impregnated melamine material.

[0005] The wear layer of the laminate in such systems is typicallyclear, such that the aesthetic appearance, including any color and/orprinted image of the decorative layer, is not obscured by the wearlayer. Further, the top surface of the wear layer is typically flat,such that the flooring panel exhibits a two-dimensional appearance tothe onlooker. Thus, while the decorative layer may exhibit an appearancethat simulates “natural” flooring materials such as hardwood or ceramictile, the typical laminate wear layer simply allows an unobstructed viewof the laminate decorative layer, and does not add to or enhance theaesthetic properties of the flooring panel.

[0006] Some prior art laminate flooring systems have includedbarely-perceptible indentations imparted to the laminate wear layer tointerrupt the aforementioned two-dimensional appearance. Those systemsfeature shallow indentations of a depth not exceeding 0.25 millimeters(“mm”). Further, the location of individual indentations or the“pattern” of indentations provided in prior art systems are unrelatedand unlinked to the aesthetic image provided by the decorative laminatelayer. Thus, any indentation pattern in prior art laminate wear layersis not related in any way to the selected aesthetic appearance of thedecorative laminate layer.

SUMMARY OF THE INVENTION

[0007] The present invention, in one embodiment, is a decorated floorpanel including a core having a top surface and an opposite bottomsurface. A decorative layer is adhered to the top surface of the coreand, in one embodiment, substantially covers the core. A desiredaesthetic appearance, such as a hardwood or ceramic tile appearance, isdisplayed by the decorative layer of the laminate. Finally, a wear layeris provided over the decorative layer, substantially covering thedecorative layer and providing protection from the ambient environment.The wear layer has an exposed wear surface with depressions therein of avariable depth below the wear surface, the depressions being arranged todisplay a desired texture pattern.

[0008] In another aspect, the present invention is a decorated floorpanel as set forth above, wherein the depressions in the wear surfacehave a depth of at least 0.50 mm below the nominal surface of the wearlayer. In this embodiment, the depressions may all be of a constantdepth or, alternatively, of a variable depth as exists for theembodiment discussed above.

[0009] In yet another aspect, the present invention is a decorated floorpanel in which the decorative layer is provided with a decorativepattern. In one embodiment, a plurality of depressions imparted to thewear layer form a desired texture pattern thereon. The relativeorientation of the texture pattern and the decorative pattern iscontrolled such that the depression pattern and the texture pattern aresubstantially in registration, creating an enhanced, three-dimensionalaesthetic appearance to the decorated floor panel.

[0010] In yet another aspect, the present invention is a floor systemcomprised of a plurality of individual decorated floor panels assembledtogether and interlocking with each other by tongue and grooveengagement, which is not visible after the floor panels are assembled.

BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS

[0011]FIG. 1 is a perspective view of an embodiment of the decoratedfloor panel according to the present invention.

[0012]FIG. 1A is an enlarged fragmentary view of an embodiment of thedecorated floor panel of FIG. 1, the texture pattern being representedout of registration with the decorative pattern.

[0013]FIG. 1B is an enlarged fragmentary view of an embodiment of thedecorated floor panel of FIG. 1, the texture pattern being representedin registration with the decorative pattern.

[0014]FIG. 2 is a section taken along lines 2-2 in FIG. 1.

[0015]FIG. 3 is a perspective cut-away view of an embodiment of thedecorated floor panel according to the present invention.

[0016]FIG. 4 is a perspective view of a group of decorated floor panelsaccording to the present invention assembled to form a portion of afloor system.

[0017]FIG. 5 is a section taken along lines 5-5 in FIG. 4.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The present invention is more particularly described in thefollowing examples that are intended as illustrative only since numerousmodifications and variations therein will be apparent to those skilledin the art. As used in the specification and in the claims, “a,” “an,”or “the” can mean one or more, depending upon the context in which it isused. The preferred embodiment is now described with reference to thefigures, in which like numbers indicate like parts throughout thefigures.

[0019] Referring to FIG. 1, the present invention, in one embodiment, isa decorated floor panel 10. In the illustrated embodiment, the panel 10is manufactured from a laminated material having a fiberboard core.Alternatively, the floor panel 10 of the invention may be manufacturedfrom other materials, including other laminates such as high pressurelaminate (“HPL”), which have been marketed under such trade names asFormica and Pergo. Other materials may also be utilized to construct thefloor panel, such as other natural, recycled or synthetic materials.

[0020] The fiberboard core laminate illustrated in FIG. 3 includes aplurality of discrete layers, including a wear layer 12, a decorativelayer 14, a core 16 and a backing layer 24. The illustrated core 16 ispreferably manufactured of fiberboard, such as that marketed bycompanies including Louisiana Pacific, Georgia Pacific, Temple Inlandand Weyerhauser. The presently preferred fiberboard core material isformed of high density fiberboard, which is a hardwood/softwood fibercompound compressed at 900-960 kg/m³. The preferred fiberboard corematerial is usually available in 4 or 5 feet widths and lengths of up to18 feet. In other embodiments, cores 16 of different materials or havingdifferent properties may be utilized, including other timber-basedproducts, such as plywood, chipboard or particleboard.

[0021] Referring now to FIGS. 2 and 3, the core 16 has a top surface 18and an opposite bottom surface 20. When installed, the bottom surface 20of the core 16 faces the underlying subfloor (not shown). FIG. 3illustrates an embodiment having an optional backing layer 24 adhered tothe bottom surface 20 of the core 16. Because the illustrated fiberboardcore is not completely impervious to moisture and contaminants, such abacking layer 24 may be provided to improve moisture resistance of thefloor panel 10. Additionally, the backing layer 24 may improvestructural integrity of the floor panel 10 by increasing overallthickness and reducing the warp and wear tendencies of uncoated corematerial. In one embodiment, a clear backing layer 24 of melamine,reinforced with aluminum oxide (AlO₂) and impregnated with athermosetting resin, is utilized. In such an embodiment, an optionallayer (not shown) may be interposed between the bottom surface 20 of thecore 16 and the backing layer 24. In one embodiment, the optional layeris constructed of paper. The optional layer may display a printed image,such as a trademark, product number or name, or any other desiredmarking or designation. In other embodiments, backing layers 24 may beconstructed of other materials providing suitable moisture resistance,such as phenolic resins or other natural, synthetic or recycledmaterials.

[0022] A decorative layer or “decor” layer 14 is adhered, joined, orcoupled to the top surface 18 of the core 16 by a chemical adhesive,mechanical connection, or other means known in the art. In theillustrated embodiment, the decorative layer 14 is a sheet of paper thatsubstantially covers the top surface 18 of the core 16. Thus, in theillustrated embodiment, the top and bottom surfaces 18, 20 of the core16 are covered by the decorative layer 14 and the backing layer 24,respectively. The visible side of the decorative layer 14, i.e., theside not adhered to the core 16, is capable of displaying a desiredaesthetic appearance, such as a color or pattern. Virtually any color orpattern may be imparted to the decorative layer 14. For example,currently contemplated patterns include simulated hardwood flooring andsimulated ceramic tile, each in a variety of styles, shades and colors.Currently contemplated simulated hardwood styles include pine, heartpine, cherry, maple, beech, oak and mahogany. Simulated tile appearancesare contemplated in a range of styles, including a variety of marble andceramic tile colors, including groutlines in ceramic tile styles. Othercurrently contemplated patterns include floral patterns, abstractdesigns, geometric designs and company logos. Other patterns may beselected by the manufacturer or user according to aesthetic preferenceor design objectives.

[0023] As mentioned above, in one embodiment the decorative layer 14 ismanufactured from paper that may be impregnated with a thermosettingresin and provided with the desired aesthetic color and/or pattern. Inother embodiments that are not shown, other materials may make up thedecorative layer 14, such as real wood veneer, pulverized stone, orother materials. Additionally, it is possible to achieve a similardecorative appearance by either a direct or indirect printing processdirectly onto the top surface 18 of the core 16. In such an embodiment,the decorative layer 14 comprises whatever ink, dye, pigment or othermarking substance applied to the core 16. Alternatively, the decorativeappearance may be provided by etching, burning or otherwise marring thetop surface 18 of the core 16. Any such treatment that supplies such adecorative appearance on the top surface 18 of the core 16 iscontemplated to comprise the decorative layer 14 as defined herein.

[0024] Referring now to FIG. 3, a wear layer 12 is provided over thedecorative layer 14, substantially covering the decorative layer 14 andproviding protection from the ambient environment. The wear layer 12 isadhered, joined, or coupled to the decorative layer 14, just as thedecorative layer 14 is joined to the underlying core 16. In oneembodiment, the wear layer 12 is comprised of a melamine sheet,reinforced with aluminum oxide (AlO₂) and impregnated with athermosetting resin. It is preferred, though not required, that thematerial selected to comprise the wear layer 12 be the same or similarmaterial as that selected to comprise the backing layer 24, if a backinglayer 24 is utilized. Using “matched” materials for those layers hasbeen found to minimize “warping” and “bowing” of the laminate material.

[0025] Alternatively, a layer of varnish or a UV curable scratchresistant coating may be used in place of the melamine sheet to comprisethe wear layer 12. As further alternatives, other materials providingsuitable moisture resistance and resilience to loads and wear to which afloor is subjected may be utilized, such as phenolic resins or othernatural, synthetic or recycled materials.

[0026] After manufacture of the laminate material, the wear layer 12 issubstantially transparent, so that the aesthetic appearance of thedecorative layer 14 is substantially unobstructed by the wear layer 12.It has been determined that the inclusion of a wear layer 12 as theoutermost layer of the laminate generally improves the resistance of thefloor panel 10 to wear, including staining or fading of the aestheticimage imparted to the decorative layer 14.

[0027] As illustrated in FIGS. 2 and 5, the outermost wear surface 26,i.e., the top surface of the wear layer 12 that is exposed to theambient environment, is provided with a textured surface condition.Thus, in addition to the decorative aesthetic image displayed by thedecorative layer 14, further aesthetic effect may be achieved byimparting depressions of a constant or variable depth to the wearsurface 26, arranged to display a desired texture pattern. For example,in the embodiment illustrated in FIG. 1 in which the decorative patternis a wood grain, a texture pattern featuring depressions designed tosimulate wood grain may be provided. As a further example, in anembodiment in which the decorative pattern is a simulated ceramic tilehaving tile portions surrounded by groutlines, a texture pattern havingan irregular simulated stone texture and roughened or non-smootheddepressions to simulate recessed grout may be provided. These examplesare merely illustrative and are not intended to be exhaustive. Otherdecorative patterns and texture patterns may be selected by themanufacturer or user according to aesthetic preference or designobjectives. When referencing depressions, one skilled in the art willappreciate that this term excludes the edges circumscribing the paneland instead encompasses “depressions” within the periphery of the edges.

[0028] In the embodiment shown in FIG. 1A, the texture pattern isimparted to the floor panel 10 without regard to the positioning of thedecorative pattern. Thus, in this embodiment, the wood grain patterndisplayed in the decorative layer 14 (depicted in dashed lines in FIG.1A) does not necessarily “match,” register with, or correspond to thewood grain pattern imparted as three-dimensional texture in the wearlayer 12 (depicted in solid lines in FIG. 1A).

[0029] In another embodiment, shown in FIG. 1B, the texture pattern andthe decorative pattern may be controlled during the manufacturingprocess such that the patterns “match.” In the hardwood floor panelexample, therefore, the textured grain pattern may be imparted to wearlayer 12 (solid lines) in registration with the visible grain pattern inthe decorative layer 14 (dashed lines). In such an embodiment, lines ofdepression in the wear layer 12 are located adjacent or substantially ontop of the printed grain lines in the decorative layer 14 of thelaminate, providing an enhanced and more realistic aesthetic appearance.

[0030] As a further example, “knothole” patterns 30 in the decorativelayer 14 are substantially overlaid by correspondingly shapeddepressions in the wear layer 12 in FIG. 1 B. Thus, in this embodiment,the hard wood flooring design displayed by the decorative layer 14includes the visual appearance of at least one knothole 30. The wearsurface 26 has at least one depression therein in registration with theknothole 30. The knothole 30 may be of a variety of shapes. In oneembodiment, the knothole 30 is substantially circular, and thecorresponding depression in registration with the knothole 30 is alsosubstantially circular in top plan view. Other embodiments arecontemplated in which the knothole 30 has other shapes, such as an ovalshape or some irregular shape similar to those found in natural hardwoodplanks. Such alternate embodiments are within the scope of the presentinvention.

[0031] In a currently contemplated hardwood embodiment, the depressionsin the wear layer 12 in registration with the decorative pattern areimparted to a depth of at least 0.30 mm below the wear surface 26. Inanother contemplated embodiment, the depressions in the wear layer 12 inregistration with the decorative pattern are imparted to a depth of atleast 0.50 mm below the wear surface 26. In still another contemplatedembodiment, the depressions are imparted to a depth of at least 1.0 mmbelow the wear surface 26. In yet other contemplated embodiments, thedepressions are imparted to a depth of at least 1.50 mm, 2.0 mm, 2.50mm, or 3.0 mm, respectively, below the wear surface 26. The possiblewidth of the depressions is unlimited, but in presently preferredembodiments, widths of between approximately 1.0 mm and 25.0 mm havebeen utilized.

[0032] Similarly, in the simulated ceramic tile embodiment shown inFIGS. 4 and 5, the texture pattern may be imparted to the wear layer 12in registration with the image imparted to the decorative layer 14. Inone embodiment, the ceramic tile design of the decorative layer 14includes the visual appearance of at least one groutline 40, and thewear layer 12 has at least one depression therein in registration withthe groutline 40. In embodiments where the groutline 40 imparted to thedecorative layer 14 is substantially square in shape, the correspondingdepression in registration with the groutline 40 is also substantiallysquare in top plan view. In another embodiments, the groutline 40 may beprovided in any selected pattern, including but not limited totriangular, hexagonal, octagonal, or other patterns. Such alternateembodiments are within the scope of the present invention.

[0033] In a currently contemplated simulated ceramic tile embodiment,the depressions in the wear layer 12 in registration with the groutline40 are imparted to a depth below the wear surface 26 of at least 0.30mm. In another contemplated embodiment, the depressions in the wearlayer 24 in registration with the groutline 40 are imparted to a depthbelow the wear surface 26 of at least 0.50 mm. In still anothercontemplated embodiment, the depressions are imparted to a depth belowthe wear surface 26 of at least 1.0 mm. In yet other contemplatedembodiments, the depressions are imparted to a depth of at least 1.50mm, 2.0 mm, 2.5 mm, or 3.0 mm, respectively, below the wear surface 26.The possible width of the depressions is unlimited, but in presentlypreferred embodiments, widths of between approximately 5.0 mm and 10.0mm have been utilized.

[0034] Also in simulated ceramic tile embodiments of the presentinvention, a “rough” simulated stone texture may be imparted to theareas of the wear layer 12 overlaying the simulated stone image 42 inthe decorative layer 14. Further, any recessed depression in the wearlayer 12 substantially overlaying the simulated groutline 40 in thedecorative layer 14 may be provided with a “rough” simulated grouttexture that is non-smooth visually and to the touch. This non-smoothand “rough” appearance more closely emulates the appearance of stone.

[0035] The selected texture pattern is usually, though not always,imparted to the wear layer 12 in a single manufacturing step, at thetime the laminate layers are laminated together. In such an embodiment,the various laminate layers are positioned within a press (not shown)having a caul plate (also not shown) provided with an inverse impressionof the selected texture pattern. After the laminate layers arepositioned within the press, the caul plate is lowered to contact thewear layer 12 of the laminate. In a single step, under heat and pressurefor a selected period of time, the layers are laminated together and thetexture pattern is imparted to the wear layer 12 by the action of thecaul plate. Through experimentation, it has been noted that satisfactoryresults may be obtained by the application of between 380-420 psi atbetween 350° F. -400° F. for a period of 18-60 seconds. These parametersare set forth by way of example only for an approximately 6.0 mm thickmelamine wear layer product sold by the Mead Corporation. It is expectedthat any of these parameters will vary depending on the degree and depthof depressions sought to be imparted to the wear layer or depending onthe characteristics of the selected wear layer material. One skilled inthe art will appreciate that after experimentation, other parameters mayproduce similarly satisfactory results.

[0036] Alternatively, the texture pattern may be imparted to the wearlayer 12 in a separate operation, after lamination of the various layersinto a single workpiece.

[0037] The depth to which the wear layer 12 is depressed to provide thefull texture patterns may be controlled during the manufacturingprocess. It is contemplated that to provide the most beneficial texturepattern, depressions of a depth at least 0.25 mm should be imparted tothe wear layer 12. More specifically, depressions of between 0.30 mm and5.75 mm in depth, more preferably between 1.0 mm and 5.75 mm in depth,and most preferably between 1.5 mm and 5.75 mm in depth, measured fromthe nominal surface of the wear layer 12, have been found to provide thegreatest aesthetic effect while not diminishing performance of theoverall floor system. These ranges are applicable in embodiments inwhich a melamine wear layer of approximately 6.0 mm thickness,manufactured by the Mead Corporation, is utilized. It has been foundthat depressions of a depth up to 0.25 mm less than the nominalthickness of such a wear layer 12 may be achieved using theabove-described manufacturing methods; that is, if the nominal thicknessis 5.0 mm, then the deepest depressions preferably should be no greaterthan 4.75 mm. In another preferred embodiment, the deepest depressionsshould be of a depth up to 0.50 mm less than the nominal thickness ofthe wear layer 12.

[0038] It is expected that if other thicknesses, materials ormanufacturing methods are selected to comprise the wear layer 12,different preferred ranges may exist for each selected material.

[0039] Additional process controls or equipment may be required tomanufacture flooring panels 10 according to embodiments of the inventionin which substantial registration between the decorative pattern and thetexture pattern are required. In a presently preferred embodiment, ashort-cycle press manufactured by Wemhoner and operated by StilesMachinery, 3965 44th St. S. E., Grand Rapids, Mich. 49512 has been foundsatisfactory for achieving such registration between the decorativepattern and the texture pattern.

[0040] During the manufacturing process, in one embodiment, the variousseparate layers are assembled in preparation for lamination. In theembodiment shown in FIG. 3, for example, a backing layer 24, a core 16,a decorative layer 14 and a wear layer 12 are stacked together beforeentering the press. Through processing equipment controls such as asingle sheet alignment system and electrostatic bonding of the variouslaminate layers prior to entry into the press, alignment between thedecorative pattern displayed by the decorative layer 14 and the texturepattern imparted to the wear layer 12 by the caul plate may be achievedwithin a tolerance of 0.125 inches.

[0041] As illustrated in FIG. 5, individual floor panels 10 according tothe invention may be assembled to form a complete floor system. Tofacilitate assembly, individual floor panels may be provided with meansfor interlocking with adjacently placed panels. As shown in FIG. 1, eachfloor panel 10 may include a first pair of parallel sides 50, 52 havingtongue and groove cuts along the first and second parallel sides 50, 52,respectively. Each such floor panel 10 further includes a second pair ofparallel sides 54, 56, perpendicular to each of the first pair ofparallel sides 50, 52, also having tongue and groove cuts. Thus, eachsuch floor panel 10 is capable of interlocking engagement with anadjacent panel. Alternatively, locking edge connections, such as thatdescribed in U.S. Pat. No. 6,006,486 to Moriau et al. (which isincorporated herein in its entirety by reference), may be utilized toform a floor covering system in which neighboring floor panels 10 aredetachably secured to one another through a mechanical interlock.

[0042] Along the edges of the floor system, perimeter panels may be cutto length as needed to fit the installation environment and fitted withmatching trim pieces (not shown) to provide an aesthetically attractivefit adjacent walls, stairs, doorways or other obstructions or transitionareas.

[0043] In a presently preferred embodiment, individual floor panels 10are manufactured to a width of 11½ inches and a length of 46{fraction(1/16)} inches, with an approximate thickness of {fraction (5/16)}inches. One skilled in the art will appreciate that other panel sizesmay be used without departing from the scope of the invention.

[0044] Although the present invention has been described with referenceto specific details of certain embodiments thereof, it is not intendedthat such details should be regarded as limitations upon the scope ofthe invention except as and to the extent that they are included in theaccompanying claims.

What is claimed is:
 1. A decorated floor panel comprising: a. a corehaving a top surface and an opposite bottom surface; b. a decorativelayer coupled to the top surface of the core, the decorative layerhaving a desired aesthetic appearance; and c. a wear layer coupled toand substantially covering the decorative layer for protecting thedecorative layer, the wear layer having an exposed wear surface withdepressions therein of a variable depth below the wear surface, thedepressions being arranged to display a desired texture pattern.
 2. Adecorated floor panel comprising: a. a core having a top surface and anopposite bottom surface; b. a decorative layer coupled to the topsurface of the core, the decorative layer having a desired aestheticappearance; and c. a wear layer coupled to and substantially coveringthe decorative layer for protecting the decorative layer, the wear layerhaving an exposed wear surface with depressions therein, at least onedepression reaching a depth of at least 0.50 millimeters below the wearsurface, the depressions being arranged to display a desired texturepattern.
 3. A decorated floor panel comprising: a. a core having a topsurface and an opposite bottom surface; b. a decorative layer coupled tothe top surface of the core, the decorative layer having a desiredaesthetic appearance; and c. a wear layer coupled to and substantiallycovering the decorative layer for protecting the decorative layer, thewear layer having an exposed wear surface with depressions therein, atleast one depression reaching a depth of at least 1.0 millimeters belowthe wear surface, the depressions being arranged to display a desiredtexture pattern.
 4. The decorated floor panel of claim 1, wherein thepanel includes a first pair of parallel sides, wherein the parallelsides have tongue and groove cuts along the parallel sides to provideinterlocking engagement.
 5. The decorated floor panel of claim 4,wherein the panel includes a second pair of parallel sides, the secondpair of parallel sides being perpendicular to each of the first pair ofparallel sides and wherein the second pair of parallel sides have tongueand groove cuts to provide interlocking engagement.
 6. The decoratedfloor panel of claim 1, wherein the core comprises fiber board.
 7. Thedecorated floor panel of claim 1, wherein the decorative layer comprisespaper and substantially covers the top surface of the core.
 8. Thedecorated floor panel of claim 1, wherein the wear layer comprisesmelamine reinforced with aluminum oxide.
 9. The decorated floor panel ofclaim 1, further comprising a backing layer coupled to and substantiallycovering the bottom surface of the core as a reinforcing element. 10.The decorated floor panel of claim 9, wherein the backing layercomprises melamine reinforced with aluminum oxide.
 11. The decoratedfloor panel of claim 1, wherein the aesthetic appearance of thedecorative layer is a hardwood flooring design.
 12. The decorated floorpanel of claim 1, wherein the aesthetic appearance of the decorativelayer is a ceramic flooring tile design.
 13. The decorated floor panelof claim 1, wherein at least one depression in the wear surface reachesa depth of at least 0.50 millimeters.
 14. The decorated floor panel ofclaim 1, wherein at least one depression in the wear surface reaches adepth of at least 1.0 millimeters.
 15. The decorated floor panel ofclaim 1, wherein at least one depression in the wear surface reaches adepth of at least 1.50 millimeters.
 16. The decorated floor panel ofclaim 1, wherein at least one depression in the wear surface reaches adepth of at least 2.0 millimeters.
 17. The decorated floor panel ofclaim 1, wherein at least one depression in the wear surface reaches adepth of at least 2.50 millimeters.
 18. The decorated floor panel ofclaim 1, wherein at least one depression in the wear surface reaches adepth of at least 3.0 millimeters.
 19. The decorated floor panel ofclaim 11, wherein the hard wood flooring design includes the visualappearance of at least one knothole, and wherein the wear surface has atleast one depression therein in registration with the knothole.
 20. Thedecorated floor panel of claim 19, wherein the knothole is substantiallycircular and wherein the corresponding depression in registration withthe knothole is also substantially circular in top plan view.
 21. Thedecorated floor panel of claim 12, wherein the ceramic flooring tiledesign includes the visual appearance of at least one groutline, andwherein the wear surface has at least one depression therein inregistration with the groutline.
 22. The decorated floor panel of claim21, wherein the groutline is substantially square and wherein thecorresponding depression in registration with the groutline is alsosubstantially square in top plan view.
 23. The decorated floor panel ofclaim 21, wherein the corresponding depression in registration with thegroutline has a non-smooth and rough texture.
 24. A decorated floorpanel comprising: a. a core having a top surface and an opposite bottomsurface; b. a decorative layer coupled to the top surface of the core,the decorative layer having an appearance of a hardwood flooring designincluding at least one knothole; and c. a wear layer coupled to andsubstantially covering the decorative layer for protecting thedecorative layer, the wear layer having an exposed wear surface withdepressions therein of a variable depth below the wear surface, thedepressions being arranged to display a desired texture patternincluding at least one depression in registration with the knothole. 25.A decorated floor panel comprising: a. a core having a top surface andan opposite bottom surface; b. a decorative layer coupled to the topsurface of the core, the decorative layer having a desired aestheticappearance forming a decorative pattern; and c. a wear layer coupled toand substantially covering the decorative layer for protecting thedecorative layer, the wear layer having an exposed wear surface having adesired texture pattern thereon, the texture pattern comprising aplurality of depressions imparted to the wear layer, the relativeorientation of the texture pattern and the decorative pattern beingcontrolled such that the decorative pattern and the texture pattern aresubstantially in registration.
 26. The decorated floor panel of claim 25wherein the aesthetic appearance of the decorative layer is a hardwoodflooring design.
 27. The decorated floor panel of claim 25 wherein theaesthetic appearance of the decorative layer is a ceramic flooring tiledesign.
 28. A floor system including at least two interlocking panels,each panel comprising: a. a core having a top surface, an oppositebottom surface, a first pair of parallel sides having tongue and groovecuts and a second pair of parallel sides having tongue and groove cuts,each of the second pair of parallel sides being perpendicular to each ofthe first pair of parallel sides; b. a decorative layer coupled to thetop surface of the core, the decorative layer having a desired aestheticappearance; and c. a wear layer coupled to and substantially coveringthe decorative layer for protecting the decorative layer, the wear layerhaving an exposed wear surface with depressions therein of a variabledepth below the wear surface, the depressions being arranged to displaya desired texture pattern.
 29. A decorated floor panel comprising: a. acore having a top surface and an opposite bottom surface; b. adecorative layer coupled to the top surface of the core, the decorativelayer having a desired aesthetic appearance; and c. a wear layer havinga thickness and being coupled to and substantially covering thedecorative layer for protecting the decorative layer, the wear layerhaving an exposed wear surface with at least one depression that extendsat least 0.50 millimeters below the wear surface and to a depth up to0.25 millimeters less than the thickness of the wear layer.
 30. Thedecorated floor panel of claim 29, wherein at least one depression inthe wear surface extends at least 0.50 millimeters below the wearsurface and to a depth up to 0.50 millimeters less than the thickness ofthe wear layer.